Hi Ferginator,
There is a lot of functionality that should and has been requested by users to be implemented with BSP/Geometry creation.
A lot of the points you’ve made above are issues that need to be addressed with the system. We currently have on our Trello UE4 Roadmap for Geometry 2.0 to be looked into at a later date. It’s a highly requested ticket by those who are new to the engine and for those who are not familiar with 3d modeling software.
[This thread may be of interest for you as well from this user. It’s their own plugin they will start developing a port of that is currently available for Unity3D.](“ProBuilder” for Unreal 4 Marketplace)
The best option to get the results you would like (since you said you’ve stuck with static meshes I’m assuming you have access to or know how to use 3d modeling software) would be to get the base shape in BSP and then create a static mesh from that, export it to your modeling software of choice, then make adjustments and refinements, then reimport into UE4.
If you have any questions feel free to ask! 